service repair manual

1. Service Information
Document Title: Function Group: Information Type: Date:
Track gearbox, description Service Information 2015/5/20
Profile:
EXC, EC160B NLC [GB]
Track gearbox, description
Track gearbox consists of a two stage planetary mechanism that converts the high speed rotation of the hydraulic motor,
into low speed, high torque rotating force at the sprocket hub.
Figure 1
Track gearbox, structure
1.
2.
3.
4.
Track motor
No.1 planetary gear assembly
No.2 planetary gear assembly
Ring gear

2. Figure 2
Track gearbox, sectional view
1 Housing 13 No.2 needle bearing 25 No.1 pin
2 Angular bearing 14 Thrust washer 26 Spring pin
3 Seal 15 No.2 pin 27 No.1 sun gear
4 Shim 16 Spring pin 28 Cover
5 Retainer 17 Thrust ring 29 Pad (thrust)
6 Screw 18 No.1 planetary gear assembly 30 Screw
7 Parallel pin 19 No.1 carrier 31 Screw
8 Ring gear 20 No.2 sun gear 32 Plug
9 Coupling 21 Retaining ring gear 33 Name plate
10 No.2 planetary gear assembly 22 No.1 planetary gear 34 O-ring
11 No.2 carrier 23 No.1 needle bearing
12 No.2 planetary gear 24 Thrust washer

3. Figure 3
Track gearbox, exploded view

4. Service Information
Document Title: Function Group: Information Type: Date:
Track gearbox, precautions
for operation
Service Information 2015/5/20
Profile:
EXC, EC160B NLC [GB]
Go back to Index Page
Track gearbox, precautions for operation
Installation
Figure 1
Mounting location
A.
B.
Main body mounted area
Sprocket mounted area





Check that the mating mount surfaces are clean.
Check that the motor is positioned correctly in the frame.
If the gearbox to frame fit is tight, draw the assembly into the frame evenly with the mounting screws.
Tighten the screws in a crisscross pattern in several stages to the specified torque.
Apply these same precautions when mounting the sprocket.
Tightening torque
Tightening torque, unit: kgf·m (lbf·ft)
Quantity Thread Tightening torque
Gearbox screw (A) 30 M16 (P2.0) 27 ± 3 (195 ± 22)
Sprocket screw (B) 22 M16 (P2.0) 27 ± 3 (195 ± 22)
NOTE!
The screws must be 10.9 KS strength classification or above.
Lubricating oil
NOTE!
Prior to operating the travel function, fill the gearbox with the specified oil to the correct level.
NOTE!
Gear specification

5. Use a gear oil equivalent to API classification GL4 / GL5 with EP (Extreme Pressure) additives
Gear oil replacement period



First (initial) oil replacement: 500 operating hours
Subsequent oil replacement: 2000 operating hours
After maintenance (initial): 250 operating hours
NOTE!
Regardless of the operating hours the gear oil must be replaced at least once per year.
NOTE!
Do not mix different types, classifications or brands of oil.
NOTE!
Drain the gear oil while it is still warm to flush out any contaminants.
Gear oil replacement procedure
Figure 2
Oil replacement location
1.
2.
3.
Fill port
Level check port
Drain port





Rotate the gearbox until the drain plug and the fill plug are on the vertical axis.
Remove the 3 plugs in the end cover and drain the oil into a suitable container.
Ensure that the drain plug O-ring is not damaged, then install the plug and torque to specification.
Refill the gearbox through the fill port until oil exits from the level check port.
Ensure that the O-ring on each plug is not damaged, then install the plugs and torque to specification.
NOTE!
Oil capacity: 5.8 Liter (1.5 gal)
Operating checks





Check the oil level prior to operating the travel function.
Check for oil leakage on the gearbox assembly.
Check for loose mounting screws.
Check for abnormal sound or vibration while rotating.
Check for any abnormal temperature increase after operating for a short time.
WARNING
The temperature of the case is high just after running. Do not touch directly by hand to prevent a burn injury. Check

6. the temperature with a surface thermometer.
NOTE!
The temperature of the case must be lower than 90 °C (194 °F), during continuous operation.

7. Service Information
Document Title: Function Group: Information Type: Date:
Track gearbox, principle of
operation
Service Information 2015/5/20
Profile:
EXC, EC160B NLC [GB]
Go back to Index Page
Track gearbox, principle of operation
Figure 1
Track gearbox, torque flow
The power transmitted from the hydraulic motor output shaft is transmitted to the 1st stage sun gear (27) → spline of 1st
carrier (19) → 2nd sun gear (20) → 2nd planetary gear (12) → ring gear (8).
At this time, the reduction ratio of reduction gear is as follows:
(1) 1st reduction ratio
i1 = ((Zs1 + Zr) · (Zs2 + Zr)) / (Zs1 · Zs2) - 1



Zs1 = No. of tooth of 1st sun gear
Zs2 = No. of tooth of 2nd sun gear
Zr = No. of tooth of ring gear

8. Service Information
Document Title: Function Group: Information Type: Date:
Track gearbox,
troubleshooting
Service Information 2015/5/20
Profile:
EXC, EC160B NLC [GB]
Track gearbox, troubleshooting
Track gearbox troubleshooting
Gearbox does not rotate. Motor overloaded. Reduce the load.
Gearbox is damaged. Replace the gearbox.
Oil leakage from mating joint
surfaces.
Liquid gasket improperly applied. Disassembly and re-apply.
Mating surface damaged. Repair or replace.
Loosen screws. Tighten to specified torque.
Loosen plug. Tighten to specified torque.
Casing leakage. Cracks or pin holes. Replace the housing.
Cover damaged. Replace the cover.
Floating seal leakage. Sliding surface worn. Replace the floating seal
assembly.
O-ring distorted.
Abnormal operating temperature. Insufficient gear oil. Refill to specified level.
Gear or bearing damaged. Replace the gearbox.

9. Hydraulic and gear oil mixed. Replace the motor oil seal.
Abnormal operating sound. Gearbox is damaged. Replace the gearbox.

10. Service Information
Document Title: Function Group: Information Type: Date:
Track gearbox, removal Service Information 2015/5/20
Profile:
EXC, EC160B NLC [GB]
Track gearbox, removal
Op nbr 00000
Figure 1
Removal, cover
1. Remove cover screw (2), and remove cover (1).
2. Remove the track.
3. Place a wooden block on the track, and place the lower roller on the block to raise the sprocket off the track.
4. Disconnect the hydraulic hoses at the track motor. Plug the pipe ends and ports to prevent the outflow of oil and
the entry of contamination.
5. Remove the track motor mounting screws from the undercarriage.
Figure 2
Removal, hydraulic hoses and screws
6. Pass a wire rope around the gearbox, and lift it. Remove the track motor as an assembly. Then, using screws in the
threaded holes of the undercarriage, force out the gearbox.

11. Figure 3
Removal, track gearbox
NOTE!
Lift the gearbox as close to the sprocket as possible to maintain balance.
NOTE!
The gearbox mounting screws may be used in the threaded frame holes.
NOTE!
Putting match-marks on the track frame and track gearbox will facilitate reassembly.

12. Service Information
Document Title: Function Group: Information Type: Date:
Track gearbox, installation Service Information 2015/5/20
Profile:
EXC, EC160B NLC [GB]
Track gearbox, installation
Op nbr 00000
NOTE!
Carefully check the mating surface of the undercarriage and the gearbox for burrs, dirt and rust scale.
1. Pass a wire rope around the gearbox, lift and install the gearbox to the undercarriage.
Figure 1
Installation, track gearbox
2. Apply loctite # 277 to the gearbox mounting screws, and tighten them to the specified torque.
 Tightening torque: 27 ± 3 kgf·m (195 ± 22 lbf·ft)
3. Connect the hydraulic hoses at the track motor.
4. Install the gearbox cover.
Figure 2
Checking, oil level
A.
B.
C.
Fill port
Level check port
Drain port

13. 5. Check the gear oil level of gearbox. If necessary, replace or refill the oil.

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15. Service Information
Document Title: Function Group: Information Type: Date:
Track gearbox,
maintenance standard
Service Information 2015/5/20
Profile:
EXC, EC160B NLC [GB]
Track gearbox, maintenance standard
The parts are precision finished and must be handled carefully.
Keep the parts of the planetary carrier (s) together, do not mix the bearings, gears, pins and thrust washers.
Seals
Replace the seals, oil seal and O-ring, although they appear not damaged.
Part replacement criteria
Replace all parts that appear damaged or are not within the allowable value.
Replace some parts in sets, i.e. gears, bearings, pins and thrust washers.
Part replacement criteria
Item No. Part Condition Allowable value
8
12
20
22
27
Ring gear
No.2 planetary gear
No.2 sun gear
No.1 planetary gear
No.1 sun gear
The tooth surface is pitted or non uniformly
worn.
The gear is cracked.
Area rate: within 5%
23
13
2
Needle bearing
Needle bearing
Angular bearing
Fitting/flaking of the balls, rollers or races.
Does not rotate smoothly by hand.
3 Seal Rust or damage on sliding face.
O-ring distorted or damaged.
15
25
No.2 pin
No.1 pin
The pin is cracked, galled or pitted.
24
14
Thrust washer Excessively worn on the face area.
Remove air in the track motor before operating.
1.
2.
3.
4.
5.
6.
7.
Check that the gearbox axis is horizontal. Rotate the gearbox housing until the drain plug is on the bottom of the
vertical axis of the end cover.
The gearbox is supplied with oil plugs (draining, filling and level) equipped with an hole that allows the air to bleed.
NOTE!
Remove the oil plugs with care. When the gearbox is warm, the air inside can be pressurized and this can cause
their strongly expulsion towards the worker.
Loose with caution the plugs (2~3 rounds) counterclockwise.
Clean the plug to be sure that the air bleed hole is not obstructed.
Wait a few seconds to allow the pressurized air to bleed from the gearbox.
Remove the plugs and let the oil flow in a large enough container; in order to facilitate the draining must be oil still
warm.
Wait a few minutes until all the oil is drained and then proceed to screw on the plugs.
Proceed with the oil fill-up following the procedures given.
NOTE!
Never mix mineral oils with synthetic oils and vice versa.

16. Do not dispose of the oil in the natural environment but be careful to eliminate it in compliance with the relative rules and
regulations that govern locally.
Tightening torque plug. See track gearbox, description.
General tools
General tools
No. Description Size Quantity
1 Socket wrench 19 mm 1
2 L wrench 5 mm
10 mm
12 mm
1
3 Torque wrench 400 ~ 1800 kgf cm 1
4 Eye bolt PF 3/4
M10
M12
2
5 Plastic hammer Approximately L = 300 ~ 500 mm 1
6 Screwdriver Approximately L = 200 mm 1
7 Depth gauge
(Vernier calliper)
Range approximately 300 mm
Min. scale 0.01 mm
1
Special tools
Special tools
No. Description Size Quantity
1 Bearing shim adjust fixture 8932-00290 Measuring plate 1

17. Service Information
Document Title: Function Group: Information Type: Date:
Track gearbox, disassembly Service Information 2015/5/20
Profile:
EXC, EC160B NLC [GB]
Track gearbox, disassembly
Op nbr 00000
Precautions






Thoroughly clean the gearbox assembly prior to disassembly.
Select a clean work area.
Match mark attached components to indicate proper positioning during reassembly.
Take care not to mix parts of sub assemblies i.e. planetary bearings, gears and thrust washers.
Thoroughly clean all parts and the inside of the casings.
Inspect and analyse all failures. – Determine the root cause!
1. Place the oil fill port and the oil drain port on the vertical axis. Remove plug (32) and drain the gear oil.
 Tools: L wrench 12 mm (PF 3/4), 8 liter pan
NOTE!
Drain oil into a clean container and check thoroughly for contamination.
Figure 1
Removal, plug
1.
2.
3.
Fill port
Level check port
Drain port
2. Remove screws (30) and remove cover (28).
 Tools: L wrench 10 mm, 5 mm

18. NOTE!
Install a screw (31) and carefully lift the cover off.
Figure 2
Removal, screw and cover
WARNING
The parts are heavy. Take appropriate safety precautions.
3. Remove No.1 planetary gear assembly (18) from No.2 planetary gear assembly (10).
Figure 3
Removal, No.1 planetary gear assembly
Disassemble No.1 planetary gear assembly.





Tap spring pin (26) into No.1 pin (25).
Remove thrust washer (24), No.1 planetary gear (22) and needle bearing (23) from No.1 carrier (19).
Remove thrust ring (17).
Remove retaining ring (21), then No.2 sun gear (20).
Remove thrust ring (17).
 Tools: Eye bolt (M10), plastic hammer

19. Figure 5
Removal, spring pins
NOTE!
Match mark gears (22), pins (25) and carrier (19).
NOTE!
Do not mix the gears, bearings, thrust washers, and pin assemblies.
NOTE!
Do not reuse spring pins (26).
NOTE!
If there are any flakes at the surface of No.1 pin, replace No.1 pin, No.1 carrier (28), No.1 planetary gear
(33) and needle bearing (34) simultaneously.
4. Remove No.1 sun gear (27) and coupling (9).
NOTE!
Remove No.1 carrier (19) and then remove No.2, No.1 sun gear (20, 27).
Figure 6
Removal, No.1 sun gear and coupling
WARNING
The parts are heavy. Take appropriate safety precautions.
5. Remove No.2 planetary gear assembly (10) from spindle (302).